How-To: Repair broken sash and clip on 2-door Coupe, back part of window sagging.
 

Tools needed:
Phillips screwdriver
Flat head screwdriver
10 mm socket and wrench

Parts needed:
GM part number: 22697622 <-- this is the clip that went on the back of the window
GM part number: 22689012 <-- this is the sash that the window slides into

Step 1 is to take off the door panel. Most of you should already know how to do that. There's 3 screws. One behind the reflector, and two behind the door handle. There's a plastic piece that pops out where the door handle is. The rest are the wonderful snaps. Snap off the arm rest with the power windows and mirror, unhook those switches. Take off the panel BUT DO NOT pull it completely away from the door. There's two more switches. One for the door locks and one for the trunk release.

Now, what worked for me is to lower the window half way down and umm...duct tape it :). I used duct tape on the window and trim pieces. No damage but some paint chipped off. That was my dad's fault though. :). You can also use scotch tape. Safer.

Step 2 is to mark off where the sash should be so that you can take it off. The sash was half the problem that broke. As you can see it snapped into two pieces. Use a flat sharp spade and hammer and carefully knock it off. I stress carefully. You don't want to break the window as well ;).



Gee I wonder what broke. (old plastic clip)



The new sash . ($17 CDN)



After the broken pieces are out, I advise you to pull the regulator out from the back side of the door. Taking out half the regulator made it 100 times easier. You will see a metal piece in black color with three screws on it. Unscrew the 3 screws and pull on the top piece so that you can pull out that metal piece.

Here's the easy part. Bend the cables to pull half the regulator out. Takes a bit of messaging but it will come out with no problems.



Now you can attach the plastic clip and the metal piece. The hard part; there's a little ball thing that goes into the clip. Massage it into the clip. The ball thing sits on the cable itself. You will see why I said to lower the window half way. This is what makes the clip go up and down with the window and the sash.

New clip is in place, at $65 CDN a clip.





At this point, bend the whole thing back into the door and replace the black metal piece. Clean the window on both sides, apply some glass primer on the window, apply body primer to the sash, and then fill the sash with urethane. That's the perfect way. I couldn't find anything because all glass shops were closed on Sunday. So I went to a carparts store and bought some all purpose sealant/adhesive. The guy knew what I wanted and told me that this should do it. I cleaned the window and applied this sealant.

I put the sash back on the window next to the tape and then attached the screw from the sash to the metal part of the clip.

Remove the duct tape or scotch tape, roll the window up and re-assemble everything.

The window has now been up for 24+ hours and I tested it successfully. Works like a charm.

thats only happened to me about, what, 5 times now... i hate how chinsey our cars are made....

I know what you mean ^^ I had mine break and stared for the longest time sitting there think why they would use a plastic piece for a mount when metal would have lasted forever. I ended up just melting the plastic back tho because my dealers and parts people around here said i have to replace the entire regulator (150) no thanks

ya, thats what i was talkin about man. i said the regulator, but i dont think i put an OR but i should have. those are the other clips i was talkin about

If you guys want the part numbers, then I can post them here as well. I will rewrite this for better clarification as well. It really is an easy job. I had to go to a few dealers before I found a dealer who said to just change the parts.

^please do, amazing how having parts numbers handy saves so much time on research and asking questions

Yup... this is the current problem with my passenger side door... broke off the window exactly like that and broke the little clips as well..

A good write up on how to fix this yourself would be awesome cause i know absolutaly nothing about power windows... I miss my classic Chevy haha.

Updated the first post. Let me know if I missed something. I will one more official and create a PDF document.

I can PDF the actual service bulletin instructions with the part numbers as well.

The more the better. Seems like this is a common issue. I wonder if they would be able to make a clip and sash out of metal instead.

Yeah, this has happend 4 times for me, and each time ended in me getting porked for about 300 bones each time. Thats why i said ta hell with it, and im doin it myself. If ya got any reading materials besides what(if) haynes says, Ill take it.

sash replacement

http://cliff_scott.home.comcast.net/...08-64-012E.pdf

window guide replacement

http://cliff_scott.home.comcast.net/...08-64-018E.pdf

can these links and pictures be updated for anybody that has problems with the windows falling.

I reposted my pictures since I moved them in photobucket. Oops.

lucas... i gotta say... THANK YOU for knowing how to use macro zoom. :lol:

links fixed...

okay my girls alero just experienced this issue. So how many clips are on the window? Are there two.....one on each end? And what the hell is a sash and how do i know that it needs to be replaced? thankz just trying to do it myself

Two clips on one window. At the dealer they couldn't tell me which one was front and rear. I returned the other one when I replaced the broken one.

The only way you'll know if the sash broke, is to take the door skin off and the plastic shield.

lucas.. looks like you need to update this again... alot of the pics aren't working...

Thanks Chris. For some reason the post kept all the old links which I replaced. Weird.

By the way, it is Lukasz.